Upper Cover

REMOVAL AND INSTALLATION
1. Set hood vertical.

Protective Cover:

2. Remove protective cover (1) from high voltage distributor. Unclip catches (arrow) and pull protective cover (1) upwards out of the guides.

Distributor Cap Screws:

3. Remove distributor cap screws (2), take off distributor cap (4) and unplug spark plug cables.
4. Open expansion tank cap to release cooling System pressure.
5. Remove heating water return line (3).

Installation Note: Replace seal.

Valve Cover:

6. Unscrew bolts (28), tightening torque 8.5 Nm (6.3 ft lbs). Take off valve cover (30) with ignition cables and distributor cap.

CAUTION: If valve cover is difficult to remove, do not strike cover with a hammer (risk of cracking and fracturing).

Distributor Rotor:

7. Unscrew bolts (5), tightening torque 2.5 Nm (1.85 ft lbs) Remove distributor rotor (6).

Driver:

8. Unscrew bolt (9), tightening torque 21 Nm (15.5 ft lbs). Pull driver (11) out by hand.
9. Take off guard cover with seal.

Removing Driver:

Insertion Sleeve:

Installation Note: Steel driver with 20 mm diameter flange must be fitted with M7 x 26 mm bolt, and aluminium driver with 21.5 mm diameter flange with M8 x 29 mm bolt.

Installation Note: The groove (arrow) in the driver (11) must engage the pin in the camshaft.

Driver 1st version 2nd version

Material Aluminum Steel
Bolt Size M8x29 M7x26
Torque 21 Nm(15.5 ft lbs) 16 Nm(12 ft lbs)
Sleeve # 103 589 00 14 00 103 589 0114 00
collar diameter 21.5 mm 20 mm

Front Cover:

10. Unscrew front cover bolts (14), tightening torque 21 Nm (15.5 ft lbs). Tap off front cover (14) with a plastic hammer. The front cover (14) is centered with two dowels.

Note: If the camshaft seal (14a) in the front cover (14) is replaced, it must be pressed in from the front until flush.

Applying Sealant:

11. As a seal, apply sealant 001 989 61 20 10 at the points marked (arrows) on the left and right sides of the oil-free groove of the timing case cover (at joint to cylinder head). Insert new seal (15) dry (without sealant) into the groove and push rearward.
12. Coat contact surfaces of front cover to cylinder head with sealant 002 989 00 20 10.

Inserting Guide Sleeve:

13. Insert guide sleeve (arrow) 103 589 00 14 00 (for camshaft diameter 21.6 mm), or 103 589 0114 (diameter 20 mm) onto camshaft. Coat sealing lip of radial seal (14a) with engine oil. Install front cover (14).
14. Tighten the two bottom bolts first, tightening torque 21 Nm (15.5 ft lbs).
15. Install in reverse sequence.
16. Top up coolant.